Compact, Lightweight, Power-Dense, Integrated Fuel Cell System

In this proposed SBIR project, Nexceris will design, develop and demonstrate an ultra-high-power-density, integrated fuel cell system (IFCS) unmanned aerial systems (UAS) power and propulsion. The targeted system will operate on military logistic fuel (JP-5 or JP-8), deliver 1 kW of power, and weigh less than 35 pounds, and the design will be scalable down to 500 watts and up to 10 kW. In Phase I of this project, Nexceris established a preliminary design for a 1-kW scale, solid oxide fuel cell (SOFC) based power system that met power density and efficiency requirements. In Phase II, high power density SOFC stacks of the targeted design will be built and tested against design requirements, and a prototype integrated fuel cell system will be built, tested to validate system operation under targeted conditions, and then delivered to NAVAIR. Successful execution of this project will result in a substantial improvement in simplicity, reliability, size and weight of SOFC-based power systems and greatly extend mission durations of unmanned aerial systems.